Corrosion-resistant granular magnetic media with improved recording performance and methods of manufacturing same

ABSTRACT

A corrosion-resistant granular magnetic recording medium with improved recording performance comprises a non-magnetic substrate having a surface; and a layer stack on the substrate surface, including, in order from the surface: a granular magnetic recording layer; an intermediate magnetic de-coupling layer; and a corrosion preventing magnetic cap layer. The intermediate magnetic de-coupling layer has an optimal thickness and/or composition for: (1) promoting magnetic exchange de-coupling between the granular magnetic recording layer and the magnetic cap layer; and (2) reducing the dynamic closure field (H cl ) for determining writeability and eraseability of the medium. Grain boundaries of the magnetic cap layer are substantially oxide-free, and have a greater density and lower average porosity and surface roughness than those of the granular magnetic recording layer.

RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 11/407,927, filed Apr. 21, 2006, naming Michael Zyee-Shan Wu,Mason Lu, Kueir W. Chour, Connie C. Liu, Edward T. Yen, Lynn Li andSteve Hwang as inventors, assigned to the assignee of the presentinvention, and having attorney docket number SEAG-STL-3780. Thisapplication is incorporated herein by reference in its entirety and forall purposes.

FIELD OF THE INVENTION

The present invention relates to improved, corrosion-resistant, highrecording performance magnetic recording media comprising a granularmagnetic recording layer and to methods of manufacturing same. Theinvention has particular utility in the manufacture and use of highareal recording density, corrosion-resistant magnetic media, e.g., harddisks, utilizing granular recording layers.

BACKGROUND OF THE INVENTION

Magnetic media are widely used in various applications, particularly inthe computer industry for data/information storage and retrievalapplications, typically in disk form, and efforts are continually madewith the aim of increasing the areal recording density, i.e., bitdensity of the magnetic media. Conventional thin film thin-film typemagnetic media, wherein a fine-grained polycrystalline magnetic alloylayer serves as the active recording layer, are generally classified as“longitudinal” or “perpendicular”, depending upon the orientation of themagnetic domains of the grains of magnetic material.

A portion of a conventional longitudinal recording, thin-film, harddisk-type magnetic recording medium 1 commonly employed incomputer-related applications is schematically illustrated in FIG. 1 insimplified cross-sectional view, and comprises a substantially rigid,non-magnetic metal substrate 10, typically of aluminum (Al) or analuminum-based alloy, such as an aluminum-magnesium (Al—Mg) alloy,having sequentially deposited or otherwise formed on a surface 10Athereof a plating layer 11, such as of amorphous nickel-phosphorus(Ni—P); a seed layer 12A of an amorphous or fine-grained material, e.g.,a nickel-aluminum (Ni—Al) or chromium-titanium (Cr—Ti) alloy; apolycrystalline underlayer 12B, typically of Cr or a Cr-based alloy; amagnetic recording layer 13, e.g., of a cobalt (Co)-based alloy with oneor more of platinum (Pt), Cr, boron (B), etc.; a protective overcoatlayer 14, typically containing carbon (C), e.g., diamond-like carbon(“DLC”); and a lubricant topcoat layer 15, e.g., of aperfluoropolyether. Each of layers 11-14 may be deposited by suitablephysical vapor deposition (“PVD”) techniques, such as sputtering, andlayer 15 is typically deposited by dipping or spraying.

In operation of medium 1, the magnetic layer 13 is locally magnetized bya write transducer, or write “head”, to record and thereby storedata/information therein. The write transducer or head creates a highlyconcentrated magnetic field which alternates direction based on the bitsof information to be stored. When the local magnetic field produced bythe write transducer is greater than the coercivity of the material ofthe recording medium layer 13, the grains of the polycrystallinematerial at that location are magnetized. The grains retain theirmagnetization after the magnetic field applied thereto by the writetransducer is removed. The direction of the magnetization matches thedirection of the applied magnetic field. The magnetization of therecording medium layer 13 can subsequently produce an electricalresponse in a read transducer, or read “head”, allowing the storedinformation to be read.

So-called “perpendicular” recording media have been found to be superiorto the more conventional “longitudinal” media in achieving very high bitdensities. In perpendicular magnetic recording media, residualmagnetization is formed in a direction perpendicular to the surface ofthe magnetic medium, typically a layer of a magnetic material on asuitable substrate. Very high linear recording densities are obtainableby utilizing a “single-pole” magnetic transducer or “head” with suchperpendicular magnetic media.

Efficient, high bit density recording utilizing a perpendicular magneticmedium requires interposition of a relatively thick (as compared withthe magnetic recording layer), magnetically “soft” underlayer (“SUL”),i.e., a magnetic layer having a relatively low coercivity below about100 Oe, such as of a NiFe alloy (Permalloy), between the non-magneticsubstrate, e.g., of glass, aluminum (Al) or an Al-based alloy, and themagnetically “hard” recording layer having relatively high coercivity,typically about 3-8 kOe, e.g., of a cobalt-based alloy (e.g., a Co—Cralloy such as CoCrPtB) having perpendicular anisotropy. The magneticallysoft underlayer serves to guide magnetic flux emanating from the headthrough the hard, perpendicular magnetic recording layer.

A typical conventional perpendicular recording system 20 utilizing avertically oriented magnetic medium 21 with a relatively thick softmagnetic underlayer, a relatively thin hard magnetic recording layer,and a single-pole head, is illustrated in FIG. 2, wherein referencenumerals 10, 11A, 4, 5, and 6, respectively, indicate a non-magneticsubstrate, an adhesion layer (optional), a soft magnetic underlayer, atleast one non-magnetic interlayer, and at least one perpendicular hardmagnetic recording layer. Reference numerals 7 and 8, respectively,indicate the single and auxiliary poles of a single-pole magnetictransducer head 16. The relatively thin interlayer 5 (also referred toas an “intermediate” layer), comprised of one or more layers ofnon-magnetic materials, serves to (1) prevent magnetic interactionbetween the soft underlayer 4 and the at least one hard recording layer6 and (2) promote desired microstructural and magnetic properties of theat least one hard recording layer.

As shown by the arrows in the figure indicating the path of the magneticflux φ, flux φ is seen as emanating from single pole 7 of single-polemagnetic transducer head 16, entering and passing through the at leastone vertically oriented, hard magnetic recording layer 5 in the regionbelow single pole 7, entering and traveling within soft magneticunderlayer 3 for a distance, and then exiting therefrom and passingthrough the at least one perpendicular hard magnetic recording layer 6in the region below auxiliary pole 8 of single-pole magnetic transducerhead 16. The direction of movement of perpendicular magnetic medium 21past transducer head 16 is indicated in the figure by the arrow abovemedium 21.

With continued reference to FIG. 2, vertical lines 9 indicate grainboundaries of polycrystalline layers 5 and 6 of the layer stackconstituting medium 21. Magnetically hard main recording layer 6 isformed on interlayer 5, and while the grains of each polycrystallinelayer may be of differing widths (as measured in a horizontal direction)represented by a grain size distribution, they are generally in verticalregistry (i.e., vertically “correlated” or aligned).

Completing the layer stack is a protective overcoat layer 14, such as ofa diamond-like carbon (DLC), formed over hard magnetic layer 6, and alubricant topcoat layer 15, such as of a perfluoropolyethylene material,formed over the protective overcoat layer.

Substrate 10 is typically disk-shaped and comprised of a non-magneticmetal or alloy, e.g., Al or an Al-based alloy, such as Al—Mg having anNi—P plating layer on the deposition surface thereof, or substrate 10 iscomprised of a suitable glass, ceramic, glass-ceramic, polymericmaterial, or a composite or laminate of these materials. Optionaladhesion layer 11, if present, may comprise an up to about 40 Å thicklayer of a material such as Ti or a Ti alloy. Soft magnetic underlayer 4is typically comprised of an about 500 to about 4,000 Å thick layer of asoft magnetic material selected from the group consisting of Ni, NiFe(Permalloy), Co, CoZr, CoZrCr, CoZrNb, CoFeZrNb, CoFe, Fe, FeN, FeSiAl,FeSiAlN, FeCoB, FeCoC, etc. Interlayer 5 typically comprises an up toabout 300 Å thick layer or layers of non-magnetic material(s), such asRu, TiCr, Ru/CoCr₃₇Pt₆, RuCr/CoCrPt, etc.; and the at least one hardmagnetic layer 6 is typically comprised of an about 100 to about 250 Åthick layer(s) of Co-based alloy(s) including one or more elementsselected from the group consisting of Cr, Fe, Ta, Ni, Mo, Pt, V, Nb, Ge,B, and Pd, iron nitrides or oxides, or a (CoX/Pd or Pt)_(n) multilayermagnetic superlattice structure, where n is an integer from about 10 toabout 25. Each of the alternating, thin layers of Co-based magneticalloy of the superlattice is from about 2 to about 3.5 Å thick, X is anelement selected from the group consisting of Cr, Ta, B, Mo, Pt, W, andFe, and each of the alternating thin, non-magnetic layers of Pd or Pt isup to about 10 Å thick. Each type of hard magnetic recording layermaterial has perpendicular anisotropy arising from magneto-crystallineanisotropy (1^(st) type) and/or interfacial anisotropy (2^(nd) type).

A currently employed way of classifying magnetic recording media is onthe basis by which the magnetic grains of the recording layer aremutually separated, i.e., segregated, in order to physically andmagnetically de-couple the grains and provide improved media performancecharacteristics. According to this classification scheme, magnetic mediawith Co-based alloy magnetic recording layers (e.g., CoCr alloys) areclassified into two distinct types: (1) a first type, whereinsegregation of the grains occurs by diffusion of Cr atoms of themagnetic layer to the grain boundaries of the layer to form Cr-richgrain boundaries, which diffusion process requires heating of the mediasubstrate during formation (deposition) of the magnetic layer; and (2) asecond type, wherein segregation of the grains occurs by formation ofnon-magnetic oxides, nitrides, and/or carbides at the boundaries betweenadjacent magnetic grains to form so-called “granular” media, whichoxides, nitrides, and/or carbides may be formed by introducing a minoramount of at least one reactive gas containing oxygen, nitrogen, and/orcarbon atoms (e.g. O₂, N₂, CO₂, etc.) to the inert gas (e.g., Ar)atmosphere during sputter deposition of the Co alloy-based magneticlayer.

Magnetic recording media with granular magnetic recording layers possessgreat potential for achieving ultra-high areal recording densities, Morespecifically, magnetic recording media based upon granular recordinglayers offer the possibility of satisfying the ever-increasing demandson thin film magnetic recording media in terms of coercivity (H_(c)),remanent coercivity (H_(cr)), magnetic remanence (M_(r)), coercivitysquareness (S*), signal-to-medium noise ratio (SMNR), and thermalstability, as determined by K_(μ)V, where K_(μ) is the magneticanisotropy constant of the magnetic material and V is the volume of themagnetic grain(s). In addition to the requirements imposed uponaforementioned magnetic performance parameters by the demand for highperformance, high areal recording density media, increasingly morestringent demands are made on the flying height of the read/writetransducer head, i.e., head-to-media separation (“HMS”). Specifically,since the read/write sensitivity (or signal) of the transducer head isinversely proportional to the spacing between the lower edge of thetransducer head and the magnetic recording layer of the media, reductionof the flying height is essential.

As indicated above, current methodology for manufacturing granular-typemagnetic recording media involves reactive sputtering of the magneticrecording layer in a reactive gas-containing sputtering atmosphere,e.g., an O₂/Ar and/or N₂/Ar atmosphere, in order to incorporate oxidesand/or nitrides therein and achieve smaller and more isolated magneticgrains. In this regard, it is believed that the introduction of O₂and/or N₂ into the Ar sputtering atmosphere provides a source of O₂and/or N₂ that migrates to the inter-granular boundaries and formsnon-magnetic oxides and/or nitrides within the boundaries, therebyproviding a structure with reduced exchange coupling between adjacentmagnetic grains. However, magnetic films formed according to suchmethodology typically are very porous and rough-surfaced compared tomedia formed utilizing conventional techniques. Corrosion andenvironmental testing of granular recording media indicate very poorresistance to corrosion and environmental influences, and evenrelatively thick carbon-based protective overcoats, e.g., ˜40 Å thick,provide inadequate resistance to corrosion and environmental attack.Studies have determined that the root cause of the poor corrosionperformance of granular magnetic recording media is incomplete coverageof the surface of the magnetic recording layer by the protectiveovercoat (typically carbon), due to high nano-scale roughness, porousoxide grain boundaries, and/or poor carbon adhesion to oxides.

Previous studies (disclosed in commonly assigned, co-pending applicationSer. No. 10/776,223, filed Feb. 12, 2004, the entire disclosure of whichis incorporated herein by reference) have demonstrated that corrosionperformance of granular magnetic recording media may be improved by ionetching (e.g., sputter etching) the surface of the granular magneticrecording layer(s) prior to deposition thereon of the carbon protectiveovercoat layer. However, a disadvantage associated with such methodologyis that since the magnetic recording layer(s) is (are) subject to direction etching, magnetic material is removed, and as a result, the magneticproperties are altered.

Another approach for improving corrosion resistance of granular magneticrecording media (disclosed in commonly assigned, co-pending applicationSer. No. 11/249,469, filed Oct. 14, 2005, the entire disclosure of whichis incorporated herein by reference) comprises formation of a thin,non-magnetic cap layer over the granular magnetic recording layer,followed by ion etching of the exposed surface of the cap layer prior todeposition of a protective overcoat layer (typically carbon-containing)thereon. An advantage afforded by provision of the cap layer is that themagnetic layer(s) underlying the cap layer is (are) effectively shieldedfrom etching, hence damage, by the ion bombardment sputter etchingprocess, and disadvantageous alteration of the magnetic properties andcharacteristics of the as-deposited, optimized magnetic recordinglayer(s) is effectively eliminated while maintaining the improvedcorrosion resistance of the media provided by etching of the mediasurface prior to deposition of the protective overcoat layer. However, adrawback of this approach is the disadvantageous increase in the HMSarising from the presence of the non-magnetic cap layer in the layerstructure overlying the granular magnetic recording layer.

Yet another approach for mitigating the problem of corrosionsusceptibility of granular magnetic recording media (disclosed incommonly assigned, co-pending application Ser. No. 11/154,637, filedJun. 17, 2005, the entire disclosure of which is incorporated herein byreference) comprises formation of a thin, magnetic cap layer containingmagnetic grains and non-magnetic grain boundaries over the granularmagnetic recording layer prior to deposition of a protective overcoatlayer (typically carbon-containing) thereon. According to this approach,the magnetic cap layer: (1) serves to protect the principal granularmagnetic recording layer from corrosion; (2) has substantiallyoxide-free grain boundaries with higher density and lower averageporosity than the grain boundaries of the principal granular magneticrecording layer; (3) has a lower average surface roughness than theprincipal granular magnetic recording layer; and (4) serves both as amagnetically functional layer and a corrosion protection layer, therebymitigating the drawback associated by the increased HMS.

The continuing requirements for increased recording density and highperformance of magnetic media, particularly in hard disk form,necessitates parallel increases in Bit Error Rate (“BER”) and SMNRrequirements. As a consequence, and notwithstanding the notableimprovements in media performance afforded by the above-describedprincipal granular magnetic recording layer+magnetic cap layer approachfor providing corrosion-resistant, high areal recording density, highperformance granular magnetic recording media, further improvement ingranular media technology and performance for meeting the increased BERand SMNR requirements of high performance disk drives is considered ofutmost significance.

In view of the foregoing, there exists a clear need for methodology formanufacturing high areal recording density, high performancegranular-type longitudinal and perpendicular magnetic recording mediawith improved corrosion resistance and optimal magnetic properties,which methodology is fully compatible with the requirements of highproduct throughput, cost-effective, automated manufacture of such highperformance magnetic recording media.

The present invention, therefore, addresses and solves theabove-described problems, drawbacks, and disadvantages associated withthe aforementioned methodology for the manufacture of high performancemagnetic recording media comprising granular-type magnetic recordinglayers, while maintaining full compatibility with all aspects ofautomated manufacture of magnetic recording media.

DISCLOSURE OF THE INVENTION

An advantage of the present disclosure is improved granular longitudinaland perpendicular magnetic recording media with improved recordingproperties and enhanced corrosion and environmental resistance,

Another advantage of the present disclosure is methods of manufacturinggranular longitudinal and perpendicular granular magnetic recordingmedia with improved recording properties and enhanced corrosion andenvironmental resistance.

Additional advantages and other features of the present disclosure willbe set forth in the description which follows and in part will becomeapparent to those having ordinary skill in the art upon examination ofthe following or may be learned from the practice of the presentinvention. The advantages of the present invention may be realized andobtained as particularly pointed out in the appended claims.

According to an aspect of the present invention, the foregoing and otheradvantages are obtained in part by a granular magnetic recording medium,comprising:

-   -   (a) a non-magnetic substrate having a surface; and    -   (b) a layer stack on the substrate surface, the layer stack        including, in order from the surface:        -   (i) a granular magnetic recording layer;        -   (ii) an intermediate magnetic de-coupling layer; and        -   (iii) a corrosion preventing magnetic cap layer.

According to embodiments of the present invention, the intermediatemagnetic de-coupling layer is comprised of a low magnetic momentmaterial; and has an optimal thickness and/or composition for: (1)promoting magnetic exchange de-coupling between the granular magneticrecording and magnetic cap layers; and (2) reducing the dynamic closurefield (H_(cl)) for determining writeability and eraseability of themedium,

Preferably, the intermediate magnetic de-coupling layer is from about 5to about 20 Å thick, preferably about 12 Å thick, and comprises a CoCrXlow magnetic moment alloy, wherein X is at least one non-magneticelement selected from the group consisting of B, Ru, Cu, Pt, Ta, Ti, V,Ag, Au, and W, and the at least one non-magnetic element X is segregatedat grain boundaries of the intermediate magnetic de-coupling layer.

Preferred embodiments of the invention include those wherein thegranular magnetic recording layer is a longitudinal or perpendicularmagnetic recording layer from about 50 to about 150 Å thick, preferablyabout 100 Å thick, and comprises a CoPtX alloy, wherein X is at leastone non-magnetic element or material selected from the group consistingof: Cr, Ta, B, Mo, V, Nb, W, Zr, Re, Ru, Cu, Ag, Hf, Ir, Y, O, Si, C,Ti, N, P, Ni, SiC, SiO₂, SiO, Si₃N₄, Al₂O₃, AlN, TiO, TiO₂, TiO_(x),TiN, TiC, Ta₂O₅, NiO, CoO, Nb₂O₅, WO₃; and Co-containing magnetic grainsare segregated by grain boundaries comprising at least one ofnon-magnetic oxides, nitrides, and carbides.

In accordance with preferred embodiments of the invention, the granularmagnetic recording layer is a perpendicular magnetic recording layer andthe layer stack further comprises a magnetically soft underlayer belowthe granular magnetic recording layer.

According to embodiments of the present invention, grain boundaries ofthe magnetic cap layer are substantially oxide-free, and have a greaterdensity and lower average porosity and surface roughness than grainboundaries of the granular magnetic recording layer.

Preferably, the magnetic cap layer is from about 40 to about 90 Å thick,preferably about 65 Å thick, and comprises a CoCrPtBX alloy, wherein Xis at least one non-magnetic element selected from the group selectedfrom the group consisting of: Cu, Au, Ta, and V; and at least one of Pt,B, and the at least one non-magnetic element X is segregated at thegrain boundaries of the magnetic cap layer.

Embodiments of the invention include media which further comprise:

-   -   (c) a protective overcoat layer on the magnetic cap layer.

Preferably, the protective overcoat layer comprises carbon.

Another aspect of the present invention is an improved method ofmanufacturing a granular magnetic recording medium, comprisingsequential steps of:

-   -   (a) providing a non-magnetic substrate including a surface;    -   (b) forming a layer stack on the surface, the layer stack        including, in order from the surface:        -   (i) a granular magnetic recording layer;        -   (ii) an intermediate magnetic de-coupling layer; and        -   (iii) a corrosion preventing magnetic cap layer.

In accordance with embodiments of the present invention, step (b)(i)comprises forming a longitudinal or perpendicular granular magneticrecording layer wherein adjacent magnetic grains are segregated by grainboundaries comprising at least one non-magnetic material; step (b)(ii)comprises forming an intermediate magnetic de-coupling layer comprisedof a low magnetic moment material, wherein the intermediate magneticde-coupling layer has an optimal thickness and/or composition for: (1)promoting magnetic exchange de-coupling between the granular magneticrecording layer and the magnetic cap layer; and (2) reducing the dynamicclosure field (H_(cl)) for determining writeability and eraseability ofthe medium; and step (b)(iii) comprises forming a magnetic cap layerwhich has substantially oxide-free grain boundaries, the grainboundaries of the magnetic cap layer having a greater density and loweraverage porosity and surface roughness than those of the granularmagnetic recording layer.

Preferred embodiments of the present invention include those whereinstep (b)(i) comprises forming a granular magnetic recording layercomprised of a CoPtX alloy, where X is at least one non-magnetic elementor material selected from the group consisting of: Cr, Ta, B, Mo, V, Nb,W, Zr, Re, Ru, Cu, Ag, Hf, Ir, Y, O, Si, C, Ti, N, P, Ni, SiC, SiO₂,SiO, Si₃N₄, Al₂O₃, AlN, TiO, TiO₂, TiO_(x), TiN, TiC, Ta₂O₅, NiO, CoO,Nb₂O₅, WO₃; and Co-containing magnetic grains are segregated by grainboundaries comprising at least one of non-magnetic oxides, nitrides, andcarbides; step (b)(ii) comprises forming an intermediate magneticde-coupling layer comprised of a CoCrX low magnetic moment alloy, whereX is at least one non-magnetic element selected from the groupconsisting of B, Ru, Cu, Pt, Ta, Ti, V, Ag, Au, and W, and the at leastone non-magnetic element X is segregated at grain boundaries of theintermediate magnetic de-coupling layer; and step (b)(iii) comprisesforming a magnetic cap layer comprised of a CoCrPtBX alloy, wherein X isat least one non-magnetic element selected from the group selected fromthe group consisting of: Cu, Au, Ta, and V; and at least one of Pt, B,and the at least one non-magnetic element X is segregated at the grainboundaries of the magnetic cap layer.

Preferably, step (b)(i) comprises forming the granular magneticrecording layer in a thickness from about 50 to about 150 Å, preferablyabout 100 Å; step (b)(ii) comprises forming the intermediate magneticlayer in a thickness from about 5 to about 20 Å, preferably about 12 Å;and step (b)(iii) comprises forming the magnetic cap layer at athickness from about 40 to about 90 Å, preferably about 65 Å.

According to further preferred embodiments of the present invention,step (b)(i) comprises forming the granular magnetic recording layer as aperpendicular recording layer and further comprises forming amagnetically soft underlayer below the perpendicular recording layer;and the method further comprises a step of:

-   -   (c) forming a protective overcoat layer on the magnetic cap        layer.

Additional advantages and aspects of the disclosure will become readilyapparent to those skilled in the art from the following detaileddescription, wherein embodiments of the present methodology are shownand described, simply by way of illustration of the best modecontemplated for practicing the present invention. As will be described,the present disclosure is capable of other and different embodiments,and its several details are susceptible of modification in variousobvious respects, all without departing from the spirit of the presentinvention. Accordingly, the drawings and description are to be regardedas illustrative in nature, and not as limitative.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of the embodiments of the presentdisclosure can best be understood when read in conjunction with thefollowing drawings, in which the same reference numerals are employedthroughout for designating like features and the various features (e.g.,layers) are not necessarily drawn to scale but rather are drawn as tobest illustrate the pertinent features, wherein:

FIG. 1 schematically illustrates, in simplified cross-sectional view, aportion of a conventional thin film longitudinal magnetic recordingmedium;

FIG. 2 schematically illustrates, in simplified cross-sectional view, aportion of a magnetic recording storage, and retrieval system comprisedof a perpendicular magnetic recording medium and a single poletransducer head;

FIG. 3 schematically illustrates, in simplified cross-sectional view, aportion of a thin film magnetic recording medium according to thepresent invention and comprising a layer stack including granularmagnetic recording, intermediate magnetic de-coupling, and magnetic caplayers;

FIGS. 4-9 are graphs illustrating various magnetic recording performanceparameters of thin film granular magnetic recording media structuredaccording to the present invention, wherein M1, M2, and M3 designate thegranular magnetic recording, intermediate magnetic de-coupling, andcorrosion preventing magnetic cap layers, respectively; and

FIG. 10 is a graph illustrating X-Ray diffraction analysis of thin filmgranular magnetic recording media structured according to the presentinvention, as a function of M2 thickness.

DESCRIPTION OF THE INVENTION

The present invention addresses and solves problems, disadvantages, anddrawbacks associated with the aforementioned poor corrosion andenvironmental resistance of high performance magnetic recording mediacomprising granular-type magnetic recording layers, as well as thenegative impact on their recording performance incurred by theabove-described remedial measures undertaken for improving corrosionresistance, and is based upon investigations by the present inventorswhich have determined that significant improvement in the bit error rate(BER) and signal-to-media noise ratio (SMNR), as well as other recordingperformance characteristics of granular magnetic recording media, can beobtained without sacrifice or diminution of the advantageous improvementin corrosion resistance afforded by the above-described cap layer(s)provided over the granular magnetic recording layer(s).

The present inventors have determined that interposition of at least onetunable intermediate magnetic layer between the granular magneticrecording layer(s) (of longitudinal or perpendicular magneticorientation) and a corrosion preventing magnetic cap layer(s) results insignificant improvement in magnetic recording parameters, whilemaintaining the enhanced corrosion resistance provided by the magneticcap layer(s). More specifically, the inventors have determined thatinterposition of such intermediate magnetic layer in proper (i.e.,optimal) thickness and/or composition ranges results in significantimprovement in magnetic recording parameters, including BER, SMNR,reverse overwrite, and DC noise.

It has been further determined that interposition of such intermediatemagnetic layer in proper (i.e., optimal) thickness and/or compositionranges results in an optimal amount of magnetic exchange de-couplingbetween the granular longitudinal or perpendicular magnetic recordinglayer(s) and the cap layer(s). Micro-magnetic modeling based upon inputof measured magnetic properties of embodiments of the present inventionindicate that a significant reduction in the dynamic closure field (Ii)is realized within certain thickness and/or composition ranges of theintermediate magnetic layer, which dynamic closure field is an importantvariable in determining eraseability/writeability of the medium.

Referring now to FIG. 3, shown therein, in simplified cross-sectionalview, is a portion of an illustrative, but non-limitative, embodiment ofa thin film magnetic recording medium 30 according to the presentinvention. As illustrated, medium 30 includes a non-magnetic substrate10, typically disk-shaped and comprised of a non-magnetic materialselected from the group consisting of: Al, NiP-plated Al, Al—Mg alloys,other Al-based alloys, other non-magnetic metals, other non-magneticalloys, glass, ceramics, polymers, glass-ceramics, and composites andlaminates of the aforementioned materials. Layer stack 31 comprising aplurality of stacked thin film layers, is formed on surface 10A ofsubstrate 10, and for purposes of the following description, comprises alower portion 31 _(L) and an upper portion 31 _(U). In embodimentsaccording to the invention wherein medium 30 is structured as alongitudinal magnetic recording medium, lower portion 31 _(L) typicallyincludes a plurality of layers, such as plating, seed, and interlayers,functionally similar to layers 11, 12A, and 12B described above inconnection with conventional longitudinal medium 1 shown in FIG. 1;whereas, in embodiments according to the invention wherein medium 30 isstructured as a perpendicular magnetic recording medium, lower portion31 _(L) typically includes a plurality of layers, such as adhesion, softmagnetic underlayer (SUL), and interlayers, functionally similar tolayers 11A, 4, and 5 described above in connection with conventionalperpendicular medium 20 shown in FIG. 2.

Still referring to FIG. 3, according to embodiments of the presentinvention wherein medium 30 is structured as a longitudinal magneticrecording medium, upper portion 31 _(U) of layer stack 31 includes agranular longitudinal magnetic recording layer 13 _(G), analogous to theconventional longitudinal magnetic recording layer 13 of conventionallongitudinal medium 1 shown in FIG. 1; whereas, according to embodimentsof the present invention wherein medium 30 is structured as aperpendicular magnetic recording medium, upper portion 31 _(U) of layerstack 31 includes a granular perpendicular hard magnetic recording layer6 _(G), analogous to the conventional perpendicular hard magneticrecording layer 6 of conventional perpendicular medium 20 shown in FIG.2.

According to preferred embodiments of the invention, granularlongitudinal magnetic recording layer 13 _(G) and granular perpendicularhard magnetic recording layer 6 _(G) are each from about 50 to about 150Å thick, preferably about 100 Å thick, and comprised of a CoPtX alloy,wherein X is at least one non-magnetic element or material selected fromthe group consisting of: Cr, Ta, B, Mo, V, Nb, W, Zr, Re, Ru, Cu, Ag,Hf, Ir, Y, O, Si, C, Ti, N, P, Ni, SiC, SiO₂, SiO, Si₃N₄, Al₂O₃, AlN,TiO, TiO₂, TiO_(x), TiN, TiC, Ta₂O₅, NiO, CoO, Nb₂O₅, WO₃; andCo-containing magnetic grains 35 are segregated by grain boundaries 34comprising at least one of non-magnetic oxides, nitrides, and carbides.

Granular longitudinal magnetic recording layer 13 _(G) and granularperpendicular hard magnetic recording layer 6 _(G) may each be formed byreactive sputter deposition techniques, e.g., magnetron sputtering,wherein segregation of the magnetic grains 35 occurs by formation ofnon-magnetic oxides, nitrides, and/or carbides at the boundaries 34between adjacent magnetic grains, which oxides, nitrides, and/orcarbides are formed by introducing a minor amount of at least onereactive gas containing oxygen, nitrogen, and/or carbon atoms (e.g. O₂,N₂, CO₂, etc.) to the inert gas (e.g., Ar) atmosphere during sputterdeposition of the Co alloy-based magnetic layer.

In a preferred embodiment, the granular magnetic recording layer isdeposited on a suitable under- or biter-layer so as to grow with an hcp<0001> preferred growth orientation, and comprises a CoPtX alloyincluding at least one non-magnetic element X such as enumerated above.Preferably, the Pt concentration is >˜10 at. %. The granular magneticrecording layer is deposited so as to form a compositionally segregatedmicrostructure wherein the magnetic particles or grains 35 comprisehigher concentrations of Co and Pt than the boundaries 34 betweenadjacent grains, while the grain boundaries comprise higherconcentrations of other non-magnetic elements and lower Coconcentration, such that the boundaries 34 are substantiallynon-magnetic. According to one embodiment, the non-magnetic grainboundaries 34 comprise CoO, whereas, according to another embodiment,the non-magnetic material of the grain boundaries 34 comprises an oxide,nitride, or carbide material derived from a sputtering target. Accordingto an especially preferred embodiment, the granular magnetic recordinglayer is sputter-deposited at a pressure >˜20 mTorr and from about 5 toabout 50 vol. % of the layer is comprised of non-magnetic grain boundarymaterial.

According to the invention, intermediate magnetic de-coupling layer 32is formed in overlying contact with granular longitudinal magneticrecording layer 13 _(G) or granular perpendicular hard magneticrecording layer 6 _(G). Layer 32 is comprised of an amorphous orcrystalline low magnetic moment material and has an optimal thicknessand/or composition for: (1) promoting magnetic exchange de-couplingbetween underlying granular magnetic recording layer(s) and overlyingmagnetic cap layer(s); and (2) reducing the dynamic closure field(H_(cl)) for determining writeability and eraseability of the medium.

Preferably, the intermediate magnetic de-coupling layer 32 is from about5 to about 20 Å thick, preferably about 12 Å thick, and comprises aCoCrX low magnetic moment alloy, wherein X is at least one non-magneticelement selected from the group consisting of: B, Ru, Cu, Pt, Ta, Ti, V,Ag, Au, and W, and the at least one non-magnetic element X is segregatedat grain boundaries of the intermediate magnetic de-coupling layer.

Formation of the intermediate magnetic de-coupling layer 32 can beaccomplished by sputter deposition similar to that utilized forconventional longitudinal media fabrication, i.e., without oxideadditives to the sputtering target or addition of reactive gas(es) tothe sputtering atmosphere. During deposition of layer 32, electricalbias and heat may be supplied to the substrate to promote segregation ofthe non-magnetic element(s) at grain boundaries of the layer, so as toprovide a suitable foundation for subsequent epitaxial growth of thecorrosion preventing magnetic cap layer thereon with dense, non-porousgrain boundaries for blocking ingress/permeation of the medium withcorrosive oxygen and other environmental substances, as described below.X-Ray analysis, as shown in the graph of FIG. 10, indicates thatinsertion of the intermediate magnetic de-coupling layer 32 between anunderlying granular magnetic recording layer(s) and overlying magneticcap layer(s) does not degrade the epitaxial structure of the latterlayers. In addition, presence of the intermediate magnetic de-couplinglayer 32 between the granular magnetic recording and magnetic cap layersmay result in enhancement of the crystal structure integrity andcorrosion protection of the magnetic cap layer.

Corrosion preventing magnetic cap layer 33 is formed in overlyingcontact with intermediate magnetic de-coupling layer 32. According toembodiments of the invention, grain boundaries 36 of the magnetic caplayer 33 are substantially oxide-free, and have a greater density andlower average porosity and surface roughness than grain boundaries 35 ofthe granular magnetic recording layer 13 _(G) or 6 _(G) forinhibiting/blocking ingress/permeation of the medium with corrosiveoxygen and other environmental substances, thereby preventing, or atleast substantially minimizing, deleterious environmentally-inducedcorrosion of the medium.

Preferably, the magnetic cap layer 33 is from about 40 to about 90 Åthick, preferably about 65 Å thick, and according to embodiments of theinvention, comprises a CoCrPtBX alloy, wherein X is at least onenon-magnetic element selected from the group selected from the groupconsisting of: Cu, Au, Ta, and V; and at least one of Pt, B, and the atleast one non-magnetic element X is segregated at the grain boundaries36 of the magnetic cap layer.

According to other preferred embodiments of the invention, the magneticcap layer 33 comprises a <0001> growth oriented film, which can besputter deposited at a gas pressure <˜20 mTorr. The magnetic cap layeris also preferably deposited without reactive oxidation, so as to form adenser microstructure than that of the granular magnetic recording layer13 _(G) or 6 _(G). According to further embodiments of the invention,the sputtering is either oxide-free or reduced in oxide contentvis-à-vis the sputtering target utilized for depositing the granularmagnetic recording layer. In each of the embodiments, the overallconcentration of non-magnetic elements, and specifically theconcentration of non-magnetic materials at the grain boundaries 36between adjacent magnetic particles or grains 37 of the magnetic caplayer 33, is lower than in the granular magnetic recording layer 13 _(G)or 6 _(G).

Medium 30 further comprises a protective overcoat layer 14, typically anabout 25 to about 45 Å thick, preferably about 35 Å thick, layer of acarbon-containing material, such as an amorphous or diamond-like carbon(DLC) material, formed by a conventional deposition process, e.g.,sputtering or ion beam deposition (IBD), in overlying contact with themagnetic cap layer 33. A suitably thick lubricant topcoat layer (notshown in FIG. 3 for illustrative simplicity), such as of aperfluoropolyethylene material, is formed (in conventional manner, e.g.,by clipping, etc.) over the protective overcoat layer 14.

FIGS. 4-9 graphically illustrate the behavior of various magneticrecording performance parameters of thin film granular magneticrecording media structured according to the present invention, as afunction of thickness of the intermediate magnetic de-coupling layer orthe remanent coercivity (H_(cr)) of the media, wherein M1, M2, and M3designate the granular magnetic recording, intermediate magneticde-coupling, and corrosion preventing magnetic cap layers, respectively.

More specifically, FIG. 4 illustrates the variation of PE-EFL (positionerror rate@error rate floor) as a function of thickness of theintermediate magnetic de-coupling layer M2; and FIG. 5 illustrates thevariation of SMNR (signal-to-media noise ratio) as a function ofthickness of the intermediate magnetic de-coupling layer M2. In eachinstance, improvement of the relevant media performance parameter isobserved when M2≦20 Å.

FIG. 6 illustrates the variation of Rev OW (reverse over-write) as afunction of the remanent coercivity (H_(cr)) of the media; and FIG. 7illustrates the variation of the eSNR-DC (equalized signal-to-noiseratio-DC) as a function of the remanent coercivity (H_(cr)) of themedia. In each instance, it is observed that reverse over-write andmedia DC erase noise (eSNR-DC) are improved only within the H_(cr) rangedictated by the M2 thickness.

FIG. 8 illustrates the variation of H_(cr) (remanent coercivity) and(coercivity) as a function of thickness of the intermediate magneticde-coupling layer M2, from which it is seen that de-coupling between M1and M3 is useful only within a specific range of M2 thickness. M1 wouldbe completely magnetically separated from M2 and M3 beyond the usefulrange of M2 thickness.

FIG. 9 illustrates the variation of H_(cl) (dynamic closure field) andJ_(exc) (exchange coupling coefficient) as a function of thickness ofthe intermediate magnetic de-coupling layer M2, from which it is seenthat a significant reduction in dynamic closure field is realized thatleads to improved writeability within a specific range of M2 thickness.

The present invention thus advantageously provides high quality,corrosion-resistant, high areal recording density longitudinal andperpendicular granular magnetic recording media with improved BER andSMNR, as well as enhancement of other pertinent magnetic recordingcharacteristics. Moreover, the inventive methodology can be practiced ina cost-effective manner, utilizing conventional manufacturing technologyand equipment (e.g., sputtering technology and equipment) for automated,large-scale manufacture of magnetic recording media, such as hard disks.Finally, the invention is not limited to use with hard disks, but ratheris broadly applicable to the formation of thermally stable, high SNR,high areal density magnetic recording media suitable for use in allmanner of devices, products, and applications.

In the previous description, numerous specific details are set forth,such as specific materials, structures, processes, etc., in order toprovide a better understanding of the present invention. However, thepresent invention, can be practiced without resorting to the detailsspecifically set forth herein. In other instances, well-known processingtechniques and structures have not been described in order not tounnecessarily obscure the present invention.

Only the preferred embodiments of the present invention and but a fewexamples of its versatility are shown and described in the presentdisclosure. It is to be understood that the present invention is capableof use in various other combinations and environments and is susceptibleof changes and/or modifications within the scope of the inventiveconcept as expressed herein.

1. A magnetic recording medium comprising: a magnetic recording layercomprising a plurality of grains separated by a plurality of grainboundaries; a second layer disposed on said magnetic recording layer;and a magnetic cap layer disposed on said second layer.
 2. The magneticrecording medium of claim 1, wherein said magnetic recording layer isselected from a group consisting of a longitudinal magnetic recordinglayer and a perpendicular magnetic recording layer.
 3. The magneticrecording medium of claim 1, wherein said magnetic recording layercomprises a CoPtX material, and wherein X is selected from a groupconsisting of Cr, Ta, B, Mo, V, Nb, W, Zr, Re, Ru, Cu, Ag, Hf, Ir, Y, O,Si, C, Ti, N, P, Ni, SiC, SiO₂, SiO, Si₃N₄, Al₂O₃, AN, TiO, TiO₂,TiO_(x), TiN, TiC, Ta₂O₅, NiO, COO, Nb₂O₅, and WO₃.
 4. The magneticrecording medium of claim 1, wherein said magnetic recording layercomprises a non-magnetic material.
 5. The magnetic recording medium ofclaim 1, wherein said plurality of grains comprise Co, and wherein saidplurality of grain boundaries comprise a material selected from a groupconsisting of non-magnetic oxide, nitride, and carbide.
 6. The magneticrecording medium of claim 1, wherein said magnetic recording layer has athickness within a range of approximately 50 Å to approximately 150 Å.7. The magnetic recording medium of claim 1 further comprising: anon-magnetic substrate; and at least one layer disposed on saidnon-magnetic substrate, wherein said magnetic recording layer isdisposed on said at least one layer.
 8. The magnetic recording medium ofclaim 7, wherein said at least one layer is selected from a groupconsisting of at least one plating layer, at least one seed layer, andat least one interlayer.
 9. The magnetic recording medium of claim 7,wherein said at least one layer is selected from a group consisting ofat least one adhesion layer, at least one soft magnetic underlay, and atleast one interlayer.
 10. The magnetic recording medium of claim 1,wherein said second layer comprises a low magnetic moment material. 11.The magnetic recording medium of claim 1, wherein said second layer isoperable to promote magnetic exchange de-coupling between said magneticrecording layer and said magnetic cap layer.
 12. The magnetic recordingmedium of claim 1, wherein said second layer is operable to reduce adynamic closure field associated with writing and erasing of saidmagnetic recording medium.
 13. The magnetic recording medium of claim 1,wherein said second layer comprises a CoCrX material, and wherein said Xis selected from a group consisting of B, Ru, Cu, Pt, Ta, Ti, V, Ag, Auand W.
 14. The magnetic recording medium of claim 13, wherein saidsecond layer comprises a second plurality of grain boundaries, andwherein said X is segregated at said second plurality of grainboundaries.
 15. The magnetic recording medium of claim 1, wherein saidsecond layer has a thickness within a range of approximately 5 Å toapproximately 20 Å.
 16. The magnetic recording medium of claim 1,wherein said magnetic cap layer comprises a second plurality of grainsseparated by a second plurality of grain boundaries.
 17. The magneticrecording medium of claim 16, wherein said second plurality of grainboundaries are substantially oxide-free, wherein said second pluralityof grain boundaries have a greater density than said plurality of grainboundaries of said magnetic recording layer, wherein further said secondplurality of grain boundaries have a lower average porosity than saidplurality of grain boundaries of said magnetic recording layer, andwherein further said second plurality of grain boundaries have a lowersurface roughness than said plurality of grain boundaries of saidmagnetic recording layer.
 18. The magnetic recording medium of claim 1,wherein said magnetic cap layer comprises a CoCrPtBX material, andwherein said X is selected from a group consisting of Cu, Au, Ta and V.19. The magnetic recording medium of claim 18, wherein said magnetic caplayer comprises a second plurality of grain boundaries, and wherein saidPt is segregated at said second plurality of grain boundaries.
 20. Themagnetic recording medium of claim 18, wherein said magnetic cap layercomprises a second plurality of grain boundaries, and wherein said B issegregated at said second plurality of grain boundaries.
 21. Themagnetic recording medium of claim 18, wherein said magnetic cap layercomprises a second plurality of grain boundaries, and wherein said X issegregated at said second plurality of grain boundaries.
 22. Themagnetic recording medium of claim 1, wherein said magnetic cap layerhas a thickness within a range of approximately 40 Å to approximately 90Å.
 23. The magnetic recording medium of claim 1 further comprising: aprotective overcoat layer disposed on said magnetic cap layer, whereinsaid protective overcoat layer comprises carbon.
 24. A method ofmanufacturing a magnetic recording medium, said method comprising:forming a magnetic recording layer comprising a plurality of grainsseparated by a plurality of grain boundaries; disposing a second layeron said magnetic recording layer; and disposing a magnetic cap layer onsaid second layer.
 25. The method of claim 24, wherein said magneticrecording layer is selected from a group consisting of a longitudinalmagnetic recording layer and a perpendicular magnetic recording layer.26. The method of claim 24, wherein said magnetic recording layercomprises a CoPtX material, and wherein X is selected from a groupconsisting of Cr, Ta, B, Mo, V, Nb, W, Zr, Re, Ru, Cu, Ag, Hf, Ir, Y, O,Si, C, Ti, N, P, Ni, SiC, SiO₂, SiO, Si₃N₄, Al₂O₃, AN, TiO, TiO₂,TiO_(X), TiN, TiC, Ta₂O₅, NiO, CoO, Nb₂O₅, and WO₃.
 27. The method ofclaim 24, wherein said magnetic recording layer comprises a non-magneticmaterial.
 28. The method of claim 24, wherein said plurality of grainscomprise Co, and wherein said plurality of grain boundaries comprise amaterial selected from a group consisting of non-magnetic oxide,nitride, and carbide.
 29. The method of claim 24, wherein said magneticrecording layer has a thickness within a range of approximately 50 Å toapproximately 150 Å.
 30. The method of claim 24 further comprising:disposing at least one layer on a non-magnetic substrate; and whereinsaid forming further comprises disposing said magnetic recording layeron said at least one layer.
 31. The method of claim 30, wherein said atleast one layer is selected from a group consisting of at least oneplating layer, at least one seed layer, and at least one interlayer. 32.The method of claim 30, wherein said at least one layer is selected froma group consisting of at least one adhesion layer, at least one softmagnetic underlay, and at least one interlayer.
 33. The method of claim24, wherein said second layer comprises a low magnetic moment material.34. The method of claim 24, wherein said second layer is operable topromote magnetic exchange de-coupling between said magnetic recordinglayer and said magnetic cap layer.
 35. The method of claim 24, whereinsaid second layer is operable to reduce a dynamic closure fieldassociated with writing and erasing of said magnetic recording medium.36. The method of claim 24, wherein said second layer comprises a CoCrXmaterial, and wherein said X is selected from a group consisting of B,Ru, Cu, Pt, Ta, Ti, V, Ag, Au and W.
 37. The method of claim 36, whereinsaid second layer comprises a second plurality of grain boundaries, andwherein said X is segregated at said second plurality of grainboundaries.
 38. The method of claim 24, wherein said second layer has athickness within a range of approximately 5 Å to approximately 20 Å. 39.The method of claim 24, wherein said magnetic cap layer comprises asecond plurality of grains separated by a second plurality of grainboundaries.
 40. The method of claim 39, wherein said second plurality ofgrain boundaries are substantially oxide-free, wherein said secondplurality of grain boundaries have a greater density than said pluralityof grain boundaries of said magnetic recording layer, wherein furthersaid second plurality of grain boundaries have a lower average porositythan said plurality of grain boundaries of said magnetic recordinglayer, and wherein further said second plurality of grain boundarieshave a lower surface roughness than said plurality of grain boundariesof said magnetic recording layer.
 41. The method of claim 24, whereinsaid magnetic cap layer comprises a CoCrPtBX material, and wherein saidX is selected from a group consisting of Cu, Au, Ta and V.
 42. Themethod of claim 41, wherein said magnetic cap layer comprises a secondplurality of grain boundaries, and wherein said Pt is segregated at saidsecond plurality of grain boundaries.
 43. The method of claim 41,wherein said magnetic cap layer comprises a second plurality of grainboundaries, and wherein said B is segregated at said second plurality ofgrain boundaries.
 44. The method of claim 41, wherein said magnetic caplayer comprises a second plurality of grain boundaries, and wherein saidX is segregated at said second plurality of grain boundaries.
 45. Themethod of claim 24, wherein said magnetic cap layer has a thicknesswithin a range of approximately 40 Å to approximately 90 Å.
 46. Themethod of claim 24 further comprising: disposing a protective overcoatlayer on said magnetic cap layer, wherein said protective overcoat layercomprises carbon.